Container Storage System for Flexible Containers

ABSTRACT

The present disclosure provides a container storage system including base tray with a flat platform having a polygonal shape and an array of spaced-apart holes, the flat platform defining a perimeter edge. The base tray also includes a substrate beneath the flat platform. The substrate defines a peripheral edge and a sidewall extends upward from the peripheral edge. A plurality of flexible containers are on the flat platform. Each flexible container has four panels, the four panels forming a body portion, a neck portion with a closure, and a tapered transition portion between the body portion and the neck portion. Each flexible container is inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform to support the inverted flexible container. One panel of at least one inverted flexible container contacts a panel of another inverted flexible container.

BACKGROUND

The present disclosure is directed to a container storage system.

Flexible packaging is known to offer significant value and sustainability benefits to product manufacturers, retailers and consumers compared to rigid solid, molded plastic packaging containers. Flexible packaging provides many consumer conveniences and benefits, including extended shelf life, easy storage, microwavability and refillability. Flexible plastic packaging is an attractive alternative to rigid mold plastic packaging because of lower production costs and smaller disposal footprint.

Conventional procedures for packaging flexible containers have shortcomings. Content-filled flexible packaging experiences instability when palletized and exposed to common transportation and/or load forces and stack weight. For example, the neck of the flexible container can change position, tipping sideways under the compressive load of successive layers. Neck tipping can lead to failure due to pinholing in the film near the neck seal, or deformation of the neck in the cap. Proposed methods to isolate neck motion during palletization involve slotting the upright necks into holes in corrugate slip sheets between layers of containers. However, these isolation systems are difficult to load due to the flexibility of the neck portion.

A need exists for a container storage system for flexible containers. A need further exists for a container storage system for palletization of flexible containers that protects palletized flexible containers from transportation and load forces, to reduce—or eliminate—damage to the palletized flexible containers.

SUMMARY

The present disclosure provides a container storage system. The container storage system includes a base tray and a plurality of flexible containers. The base tray includes a flat platform with a polygonal shape having an array of spaced-apart holes, the flat platform defining a perimeter edge. The base tray also includes a substrate beneath the flat platform. The substrate defines a peripheral edge and a sidewall extends upward from the peripheral edge. The plurality of flexible containers are on the flat platform. Each flexible container has four panels, the four panels forming a body portion, a neck portion with a closure, and a tapered transition portion between the body portion and the neck portion. Each flexible container is inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform to support the inverted flexible container. One panel of at least one inverted flexible container contacts a panel of another inverted flexible container.

The present disclosure also provides a container storage system including a base tray and a first set of flexible containers. The base tray includes a flat platform with a polygonal shape having an array of spaced-apart holes, the flat platform defining a perimeter edge. The base tray also includes a substrate beneath the flat platform. The substrate defines a peripheral edge and a sidewall extends upward from the peripheral edge. The first set of flexible containers are on the flat platform. Each flexible container has four panels, the four panels forming a body portion, a neck portion with a closure, and a tapered transition portion between the body portion and the neck portion. Each flexible container is inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform to support the inverted flexible container. One panel of at least one inverted flexible container contacts a panel of another inverted flexible container. The container storage system further includes a retainer tray extending across bottom segments of the inverted flexible containers of the first set. The retainer tray includes a retainer platform with a retainer array of spaced-apart holes. The retainer platform defines a retainer perimeter edge and a retainer sidewall extends upward from the retainer perimeter edge. A second set of flexible containers is on the retainer tray. Each flexible container of the second set is inverted such that the neck portion extends downward through a respective hole of the retainer platform, and the closure of at least one flexible container in the second set contacts a base segment of an inverted flexible container on the flat platform.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a container storage system with a base tray and a plurality of flexible containers in accordance with an embodiment of the present disclosure.

FIG. 2 is an exploded view of the container storage system of FIG. 1.

FIG. 3 is a cross-sectional view of the container storage system taken along line 3-3 of FIG. 1 in accordance with an embodiment of the present disclosure.

FIG. 4 is a cross-sectional view of the container storage system taken along line 3-3 of FIG. 1 in accordance with another embodiment of the present disclosure.

FIG. 5 is an exploded view of a container storage system in accordance with an embodiment of the present disclosure.

FIG. 6 is a perspective view of a container storage system in accordance with an embodiment of the present disclosure.

FIG. 7 is a perspective view of a container storage system with a base tray, a plurality of flexible containers, a retainer tray, and a second set of flexible containers in accordance with another embodiment of the present disclosure.

FIG. 8 is a cross-sectional view of the container storage system taken along line 8-8 of FIG. 7 in accordance with an embodiment of the present disclosure.

FIG. 9 is a perspective view of a container storage system in accordance with an embodiment of the present disclosure.

FIG. 9A is a top plan view of the container storage system of FIG. 9.

FIG. 9B is a top plan view of the container storage system of FIG. 9.

FIG. 10A is a perspective view of a container storage system and a forklift in accordance with an embodiment of the present disclosure.

FIG. 10B is a perspective view of a container storage system and a forklift in accordance with another embodiment of the present disclosure.

FIG. 11 is a perspective view of a container storage system in accordance with an embodiment of the present disclosure.

FIG. 12 is a perspective view of a container storage system and a container storage system inversion apparatus in accordance with an embodiment of the present disclosure.

FIG. 13 is a perspective view of a container storage system on a container storage system inversion apparatus in accordance with an embodiment of the present disclosure.

FIG. 14 is an exploded view of an inverted container storage system in accordance with an embodiment of the present disclosure.

FIG. 15 is a perspective view of an inverted container storage system in accordance with an embodiment of the present disclosure and a consumer.

DEFINITIONS

Any reference to the Periodic Table of Elements is that as published by CRC Press, Inc., 1990-1991. Reference to a group of elements in this table is by the new notation for numbering groups.

For purposes of United States patent practice, the contents of any referenced patent, patent application or publication are incorporated by reference in their entirety (or its equivalent US version is so incorporated by reference) especially with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art.

The numerical ranges disclosed herein include all values from, and including, the lower value and the upper value. For ranges containing explicit values (e.g., 1 or 2, or 3 to 5, or 6, or 7) any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).

Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight, and all test methods are current as of the filing date of this disclosure.

The term “composition,” as used herein, refers to a mixture of materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.

The terms “comprising,” “including,” “having,” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically delineated or listed.

A “polymer” is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating “units” or “mer units” that make up a polymer. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term copolymer, usually employed to refer to polymers prepared from at least two types of monomers. It also embraces all forms of copolymer, e.g., random, block, etc. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of copolymer as described above prepared from polymerizing ethylene or propylene respectively and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being “made of” one or more specified monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, in this context the term “monomer” is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to has being based on “units” that are the polymerized form of a corresponding monomer.

An “olefin-based polymer” or “polyolefin” is a polymer that contains more than 50 mole percent polymerized olefin monomer (based on total amount of polymerizable monomers), and optionally, may contain at least one comonomer. Non-limiting examples of olefin-based polymer include ethylene-based polymer and propylene-based polymer.

An “ethylene-based polymer” is a polymer that contains more than 50 weight percent polymerized ethylene monomer (based on the total weight of polymerizable monomers) and, optionally, may contain at least one comonomer.

A “propylene-based polymer” is a polymer that contains more than 50 weight percent polymerized propylene monomer (based on the total weight of polymerizable monomers) and, optionally, may contain at least one comonomer.

DETAILED DESCRIPTION

The present disclosure provides a container storage system. The container storage system includes a base tray and a plurality of flexible containers. The base tray includes a flat platform with a polygonal shape having an array of spaced-apart holes, the flat platform defining a perimeter edge. The base tray also includes a substrate beneath the flat platform. The substrate defines a peripheral edge and a sidewall extends upward from the peripheral edge. The plurality of flexible containers are on the flat platform. Each flexible container has four panels, the four panels forming a body portion, a neck portion with a closure, and a tapered transition portion between the body portion and the neck portion. Each flexible container is inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform to support the inverted flexible container. One panel of at least one inverted flexible container contacts a panel of another inverted flexible container.

A. Base Tray

The container storage system 100 includes a base tray 20, as shown in FIGS. 1-4. The base tray 20 includes a flat platform 22 with a polygonal shape having an array of spaced-apart holes 24, the flat platform 22 defining a perimeter edge 26, as shown in FIG. 2. The base tray 20 also includes a substrate 28 beneath the flat platform 22. The substrate 28 defines a peripheral edge 30 and a sidewall 32 extends upward from the peripheral edge 30. In an embodiment, the base tray 20 includes a support platform 34, as shown in FIG. 2.

i. Flat Platform

As shown in FIGS. 1-4, the base tray 20 includes a flat platform 22.

In an embodiment, the flat platform 22 is formed from a fiberboard. Nonlimiting examples of suitable materials to form a fiberboard include wood, paper, polymeric material, and combinations thereof (such as a composite). In an embodiment, the fiberboard is coated to provide a water-proof or water-resistant fiberboard. A nonlimiting example of a suitable polymeric material is a polyolefin. In an embodiment, the fiberboard is a corrugated fiberboard. A nonlimiting example of a corrugated fiberboard is corrugated cardboard. Corrugated fiberboard includes a fluted sheet and a flat wall. A “fluted sheet” is a wave-shaped material that forms the fiberboard's corrugation. Each wave-shape defines a “flute.” The properties of standard flutes are provided in Table 1A. Nonlimiting examples of suitable corrugated fiberboard include fluted sheets as shown in Table 1A below, and combinations thereof.

TABLE 1A Standard Flute Properties Flute Flute Flutes Per Flute Flutes per Thickness Designation Linear Foot Thickness (in) Linear Meter (mm) A flute 33 ± 3 3/16 108 ± 10 4.8 B flute 47 ± 3 ⅛  154 ± 10 3.2 C flute 39 ± 3 5/32 128 ± 10 4.0 E flute 90 ± 4 1/16 295 ± 13 1.6 F flute 125 ± 4  1/32 420 ± 13 0.8

Further nonlimiting examples of suitable corrugated fiberboard configurations include single face, single wall, double wall, and triple wall corrugated fiberboard, the configurations of which are detailed in Table 1B, below.

TABLE 1B Standard Corrugated Fiberboard Configurations Configuration* Single Face Fluted Sheet/Flat Wall Single Wall Flat Wall/Fluted Sheet/Flat Wall Double Wall Flat Wall/Fluted Sheet/Flat Wall/Fluted Sheet/Flat Wall Triple Wall Flat Wall/Fluted Sheet/Flat Wall/Fluted Sheet/Flat Wall/ Fluted Sheet/Flat Wall *Sheets and walls separated by a “/” symbol are adjacent and joined to one another

Each of the fluted sheets of a double wall or triple wall corrugated fiberboard may have the same or different properties. In an embodiment, the corrugated fiberboard is a single wall corrugated fiberboard with a “C flute” fluted sheet. In another embodiment, the corrugated fiberboard is a double wall corrugated fiberboard with a “B flute” fluted sheet and a “C flute” fluted sheet.

The flat platform 22 can have an ovoid shape or a polygonal shape. In an embodiment, the flat platform 22 has a polygonal shape. A “polygonal shape” is a closed-plane figure bounded by at least three sides. Nonlimiting examples of suitable polygonal shapes include triangle, square, rectangle, parallelogram, hexagon and octagon.

In an embodiment, the flat platform 22 has a perimeter edge 26 that defines a rectangular shape, as shown in FIGS. 1 and 2.

The flat platform 22 has an array of spaced-apart holes 24, as shown in FIGS. 1 and 2. The array of spaced-apart holes 24 is ordered such that each hole is evenly spaced apart from one another. Each hole 24 extends through the flat platform 22, as shown in FIG. 3. In an embodiment, each hole 24 is in the shape of a circle, an oval, or an ovoid. FIGS. 1 and 2 depict an array of spaced-apart holes 24, wherein each hole 24 is in the shape of a circle.

In an embodiment, the flat platform 22 includes from 2, or 4, or 6, or 9, or 12, or 16, or 20, or 25 to 30, or 36, or 42, or 56, or 64, or 72, or 81, or 90, or 100, or 150, or 200, or 250, or 300, or 350, or 400, or 450, or 500 holes.

In an embodiment, the flat platform 22 has a rectangular shape and an array of 42 spaced-apart holes 24, and each hole 24 is in the shape of a circle, as shown in FIG. 2.

The flat platform may comprise two or more embodiments disclosed herein.

ii. Substrate and Sidewall

As shown in FIGS. 2-4, the base tray 20 includes a substrate 28.

In an embodiment, the substrate 28 is formed from a corrugated fiberboard. The corrugated fiberboard may be any corrugated fiberboard previously described herein.

The substrate 28 has the same shape as the flat platform 22. In an embodiment, the substrate 28 has a polygonal shape. The polygonal shape may be any polygonal shape previously disclosed herein. In an embodiment, substrate 28 has a rectangular shape, as shown in FIG. 2.

The substrate 28 defines a peripheral edge 30, as shown in FIG. 2. A sidewall 32 extends upward from the peripheral edge 30, as shown in FIGS. 2-4. In an embodiment, the sidewall 32 is joined to the substrate 28 at the peripheral edge 30. In an embodiment, the sidewall 32 and the substrate 28 are formed from an integral sheet of corrugated fiberboard.

The substrate 28 is located beneath the flat platform 22, as shown in FIG. 2. The flat platform 22 is located above the substrate 28 and within the sidewall 32, as shown in FIGS. 1-4. In an embodiment, the flat platform 22 contacts the substrate 28.

The sidewall 32 has a height, H_(BS), as shown in FIGS. 3 and 4. The height, H_(BS), of the sidewall 32 is sufficient to extend upward beyond the flat platform 22, as shown in FIGS. 1, 3 and 4. In an embodiment, the sidewall 32 has a height, H_(BS), from 2.50 cm (1 inch), or 5.1 cm (2 inches) to 7.6 cm (3 inches), or 10.2 cm (4 inches), or 12.7 cm (5 inches), or 25.4 cm (10 inches), or 38.1 cm (15 inches), or 50.8 cm (20 inches), or 63.5 cm (25 inches), or 76.2 cm (30 inches).

In an embodiment, the base tray 20 has four corners (36 a, 36 b, 36 c, 36 d), as shown in FIG. 5.

The substrate may comprise two or more embodiments disclosed herein.

The sidewall may comprise two or more embodiments disclosed herein.

iii. Support Platform

In an embodiment, the base tray 20 includes a support platform 34, as shown in FIGS. 2-4. The support platform 34 is formed from a corrugated fiberboard. The corrugated fiberboard may be any corrugated fiberboard previously described herein. The support platform 34 has the same shape as the flat platform 22, as shown in FIG. 2. In an embodiment, the support platform 34 has a polygonal shape. The polygonal shape may be any polygonal shape previously disclosed herein.

The support platform 34 defines a support perimeter edge 35, as shown in FIG. 2.

The support platform 34 has a support array of spaced-apart holes 33, as shown in FIG. 2. The support array of spaced-apart holes 33 may be any array of spaced-apart holes previously described herein. Each hole 33 in the support platform 34 aligns with a hole 24 in the flat platform 22, as shown in FIGS. 2-4.

The support platform 34 is located between the substrate 28 and the flat platform 22. The support platform 24 is located above the substrate 28 and below the flat platform 22, and within the sidewall 32, as shown in FIGS. 2-4. In an embodiment, the support platform 34 contacts the substrate 28 and the flat platform 22.

In an embodiment, the base tray 20 includes from 0, or 1, or 2, or 3 to 4, or 5, or 10, or 15 support platforms 34. FIGS. 2, 3 and 4 depict a base tray 20 with two support platforms 34 located between the substrate 28 and the flat platform 22.

The support platform may comprise two or more embodiments disclosed herein.

The base tray may comprise two or more embodiments disclosed herein.

B. Plurality of Flexible Containers

The container storage system 100 includes a plurality of flexible containers 300, as shown in FIGS. 1-5. The plurality of flexible containers 300 are on the flat platform 22.

Each flexible container 300 has four panels 302. Each panel 302 is composed of a flexible film including a polymeric material. The flexible film may be a single layer structure or a multilayer structure. Nonlimiting examples of suitable polymeric material include nylon, polyolefin, and combinations thereof. Nonlimiting examples of suitable polyolefin includes ethylene-based polymers, propylene-based polymers, and combinations thereof. The flexible film is resilient, flexible, deformable and pliable. The structure and composition of the flexible film for each panel 302 may be the same or different. In an embodiment, each of the four panels 302 is composed of a flexible film having the same structure and the same composition.

The four panels 302 are folded to form gussets, and heat sealed in a perimeter shape to form a gusseted body portion 304. Thus, each of the four panels 302 is sealed to two other panels 302 to form a body portion 304 of the flexible container 300, as shown in FIG. 2. The gusseted body portion 304 expands to form a flexible container 300 with a square or a rectangular cross-section. FIG. 2 depicts a body portion 304 expanded to form a flexible container 300 with a rectangular cross-section. The gussets terminate at the bottom segment 314 of the flexible container 300 to form a substantially flat, or flat, base, as shown in FIG. 3. The bottom segment 314 provides stability when the flexible container is partially or wholly filled and in a free-standing upright position on a flat surface. In an embodiment, the gussets also terminate at the top of the flexible container to form an open neck portion 306 for receiving a closure, as shown in FIGS. 3 and 4. In an embodiment, the neck portion 306 is top-centered, as shown in FIGS. 1 and 2. Between the body portion 304 and the neck portion 306 is a tapered transition portion 310. FIG. 4 depicts the tapered transition portion 310 of a flexible container 300. In the tapered transition portion 310, each of the four panels 302 is sealed to two other panels 302 along a tapered seal.

The neck portion 306 of the flexible container 300 includes a closure. The closure may or may not be re-closable. Nonlimiting examples of suitable closures include fitments 308, heat seal closures, press-seal closures, zipper closures, tear-away closures, microcapillary closures, and combinations thereof.

In an embodiment, the present flexible container 300 includes a fitment 308 inserted into the neck portion 306 of the flexible container 300, as shown in FIGS. 3 and 4. The neck portion 306 is sized to accommodate the fitment 308. The fitment 308 is flexible or rigid. In an embodiment, the fitment 308 is composed of a polymeric material. The polymeric material may be any polymeric material previously disclosed herein. In another embodiment, the fitment 308 is located in a panel 302 of the flexible container 300. In another embodiment, the fitment 308 is located at a seal between two panels 302.

The fitment 308 is closed and is re-closable. Nonlimiting examples of suitable fitments 308 include screw caps, flip-top caps, snap caps, liquid or beverage dispensing fitments (stop-cock or thumb plunger), Colder fitment connector, tamper evident pour spout, vertical twist cap, horizontal twist cap, aseptic cap, vitop press, press tap, push on tap, lever cap, conro fitment connector, and other types of removable (and optionally reclosable) fitments. The fitment 308 may or may not include a gasket. In an embodiment, the fitment 308 is watertight. In a further embodiment, the fitment 308 provides a hermetic seal to the flexible container 300.

In an embodiment, the flexible container 300 has a volume from 0.5 liter, or 1 liter, or 2 liters, or 3 liters, or 3.5 liters, or 3.8 liters to 4 liters, or 5 liters, or 6 liters, or 7 liters, or 8 liters, or 9 liters, or 10 liters, or 15 liters, or 20 liters.

The flexible container 300 is expanded (i.e., not collapsed). An “expanded” flexible container has a body portion 304 with a square or a rectangular cross-section.

The flexible container 300 contains a fluid composition 318. The fluid composition 318 is a substance that is fluidly deliverable when dispensed from the flexible container 300, the fluid composition 318 flowing out of the flexible container 300 when the closure is opened. The fluid composition 318 can be a liquid, a paste, a foam, a powder, or any combination thereof. Nonlimiting examples of suitable fluid compositions 318 include:

-   -   food products, such as mayonnaise, ketchup, mustard, sauces,         desserts (whipped cream), spreads, oil, pastry components,         grease, butter, margarine, sauces, baby food, salad dressing,         condiments, beverages, syrup, soup, water, juice, milk, honey;     -   personal care products such as toothpaste, cosmetics creams,         lotions, skin care products, hair gels, personal care gel,         liquid soap, liquid shampoo, sun care products, shaving cream,         deodorant;     -   medicaments, pharmaceutical and medical products such as         medications (including dosage packages) and ointments, oral and         nasal sprays;     -   household products such as polishes and glass, bathroom and         furniture and other cleaners, insecticides, air fresheners,         detergents; and     -   industrial products such as paints, lacquers, glues, grease and         other lubricants, oil sealants, motor oil, fuel additives,         pastes, chemicals, insecticides, herbicides, fire extinguishing         components.

In an embodiment, each flexible container 300 contains from 0.5 liter, or 1 liter, or 2 liters, or 3 liters, or 3.5 liters, or 3.8 liters to 4 liters, or 5 liters, or 6 liters, or 7 liters, or 8 liters, or 9 liters, or 10 liters, or 15 liters, or 20 liters of a fluid composition 318. In an embodiment, each flexible container 300 contains 3.8 liters (1 gallon) of a fluid composition 318.

In an embodiment, each flexible container 300 contains a fluid composition 318, and the combined weight of the flexible container 300 and the fluid composition 318 is from 100 grams (g), or 500 g, or 750 g, or 900 g, or 1.00 kilogram (kg), or 1.50 kg to 2.00 kg, or 2.50 kg, or 3.00 kg, or 3.50 kg, or 3.63 kg, or 4.00 kg, or 4.50 kg, or 5.00 kg.

In an embodiment, the flexible container 300 has a handle 312. Although FIG. 4 depicts a flexible container 300 with two handles 312 (a top handle and a bottom handle), it is understood that the flexible container 300 may be fabricated without handles 312, or with only one handle 312.

Nonlimiting examples of suitable flexible containers 300 include the PacXpert™ package available from The Dow Chemical Company, and the flexible containers disclosed in U.S. Pat. No. 8,231,029; U.S. Pat. No. 8,348,509; US Pub. No. 2015/0314928 and US Pub. No. 2015/0314919, the content of each incorporated herein by reference.

Each flexible container 300 is inverted such that the tapered transition portion 310 extends upward from the neck portion 306 and the body portion 304 extends upward from the tapered transition portion 310, as shown in FIG. 4. Each flexible container 300 is inverted such that the neck portion 306 extends downward through, or partially through, a respective hole 24 of the flat platform 22 and the tapered transition portion 310 contacts the flat platform 22 to support the inverted flexible container 300. In an embodiment, each flexible container 300 is inverted such that the neck portion 306 extends downward through, or partially through, a respective hole 24 of the flat platform 22 and a respective hole 33 of the support platform 34, and the tapered transition portion 310 contacts the flat platform 22 to support the inverted flexible container 300.

FIG. 3 depicts a base tray 20 and two inverted flexible containers 300. The neck portion 306 of each flexible container 300 extends downward through a respective hole 24 in the flat platform 22 and a respective hole 33 in two support platforms 34. The tapered transition portion 310 of each flexible container 300 contacts the flat platform 22 to support the inverted flexible container 300.

FIG. 4 depicts a base tray 20 and two inverted flexible containers 300 being placed into the base tray 20. Before being placed into the base tray 20, the flexible container 300 has a width, W₁. As the flexible container 300 is lowered, (i) the neck portion 306 of the flexible container 300 extends downward through a respective hole 24 in a flat platform 22 and (ii) the tapered transition portion 310 contacts the flat platform 22 and flattens under the weight of the container contents, displacing the contents of the flexible container 300. Displacement of the contents of the flexible container 300 causes the flexible container 300 to have a width, W₂, that is greater than the width, W₁. After the flexible container 300 is placed into the base tray 20, the tapered transition portion 310 is flat and contacts the flat platform 22, as shown in FIGS. 3 and 4. The flexible container 300 with a flat transition portion 310 contacting the flat platform 22 has a width, W₃, that is greater than W₂, as shown in FIG. 4. The tapered transition portion 310 contacts the flat platform 22 to form a support interface.

One panel 302 of at least one inverted flexible container 300 contacts a panel 302 of another inverted flexible container 300, as shown in FIG. 3. In an embodiment, two panels 302 of at least one inverted flexible container 300 contact a respective panel 302 from two other individual inverted flexible containers 300, as shown by Container A of FIG. 4. In an embodiment, three panels 302 of at least one inverted flexible container 300 contact a respective panel 302 from three other individual inverted flexible containers 300. In another embodiment, four panels 302 of at least one inverted flexible container 300 contact a respective panel 302 from four other individual inverted flexible containers 300. The contacting panels 302 may or may not be co-extensive with each other. Co-extensive panels 302 are panels with the same spatial scope, or are of the same size. The flexible containers 300 may have like orientation (side-to-side-to-side) or mixed orientation (side-to-front-to-side).

In an embodiment, one panel 302 of at least one inverted flexible container 300 contacts the sidewall 32, as shown in FIGS. 3 and 4. In another embodiment, two panels 302 of at least one inverted flexible container 300 contact the sidewall 32, and the other two panels 302 of the at least one inverted flexible container 300 contact a respective panel 302 from two other inverted flexible containers 300.

In an embodiment, the container storage system 100 includes from 2, or 4, or 6, or 9, or 12, or 16, or 20, or 25 to 30, or 36, or 42, or 56, or 64, or 72, or 81, or 90, or 100, or 126, or 150, or 200, or 250, or 300, or 350, or 400, or 450, or 500 flexible containers.

In an embodiment, the number of holes 24 in the flat platform 22 is equal to the number of flexible containers 300 included in the container storage system 100.

In an embodiment, the neck portion 306 of each flexible container 300 extends downward through, or partially through, a respective hole 24 in the array, and the flat platform 22 is covered by inverted flexible containers 300. A flat platform 22 that is covered by inverted flexible containers 300 is not visible from a top plan view.

The flat platform 22, combined with any optional support platform 34 in the base tray 20, has a height, H_(p), as shown in FIG. 4. The combined height of the flat platform 22 and optional support platform, H_(p), is such that a neck portion 306 extending through, or partially through, a respective hole 24 in the flat platform 22, and optionally a respective hole 33 in the support platform 34, is suspended above the substrate 28 and does not contact the substrate 28.

In an embodiment, the plurality of flexible containers 300 with a tapered transition portion 310 in contact with the flat platform 22 define a first set of flexible containers 300.

The plurality of flexible containers 300 may be manually or automatically inverted and placed in the base tray 20. When the flexible containers 300 are inverted, the neck portion 306 self-centers under the force of gravity. Thus, the flexible containers 300 can be quickly and easily loaded into the base tray 20. In an embodiment, the panels 302 of the flexible container 300 are slightly compressed, which enhances the self-centering ability of the neck portion 306.

The base tray 20 and the plurality of flexible containers 300 define a base layer. The base layer has a height, H_(BL), as shown in FIG. 3. In an embodiment, the height of the sidewall 32, H_(Bs), is from 10%, or 15%, or 20%, to 25%, or 30%, or 40%, or 50%, or 60%, or 70%, or 75%, or 80%, or 90%, or 95%, or 100% of the height of the base layer, H_(BL).

The plurality of flexible containers 300 may comprise two or more embodiments disclosed herein.

C. Retainer Tray

In an embodiment, the container storage system 200 includes a retainer tray 44, as shown in FIGS. 7-9. The retainer tray 44 includes a retainer platform 46 with a retainer array of spaced-apart holes 47. The retainer platform 46 defines a retainer perimeter edge 48. A retainer sidewall 50 extends upward from the retainer peripheral edge 48.

i. Retainer Platform

The retainer tray 44 includes a retainer platform 46, as shown in FIGS. 7 and 8.

In an embodiment, the retainer platform 46 is formed from a corrugated fiberboard. The corrugated fiberboard may be any corrugated fiberboard previously described herein.

The retainer platform 46 has a polygonal shape. The polygonal shape may be any polygonal shape previously disclosed herein. In an embodiment, the retainer platform 46 has the same polygonal shape as the flat platform 22, as shown in FIG. 7.

The retainer platform 46 defines a retainer perimeter edge 48, as shown in FIG. 7.

The retainer platform 46 has a retainer array of spaced-apart holes 47, as shown in FIG. 7. The retainer array of spaced-apart holes 47 may be any array of spaced-apart holes previously described herein. In an embodiment, each hole 47 in the retainer platform 46 aligns with a hole 24 in the flat platform 22, as shown in FIG. 8. In an embodiment, the retainer platform 46, the support platform 34 and the flat platform 22 each has an ordered array of 42 evenly spaced holes (24, 33, 47) and each hole 47 in the retainer platform 46 is aligned with a hole 24 in the flat platform 22, which is aligned with a hole 33 in the support platform 34.

The retainer platform 46 extends across the bottom segments 314 of the inverted flexible containers 300.

In an embodiment, the retainer tray 44 includes from 1, or 2, or 3, or 4 to 5, or 6, or 7, or 8, or 9, or 10 retainer platforms 46.

The retainer platform may comprise two or more embodiments disclosed herein.

ii. Retainer Sidewall

As shown in FIGS. 7 and 8, the retainer tray 44 includes a retainer sidewall 50.

The retainer sidewall 50 extends upward from the retainer perimeter edge 48, as shown in FIG. 7. In an embodiment, the retainer sidewall 50 is joined to the retainer platform 46 at the retainer perimeter edge 48. In an embodiment, the retainer sidewall 50 and the retainer platform 46 are formed from an integral sheet of corrugated fiberboard.

The retainer sidewall 50 has a height, H_(RS), as shown in FIG. 8. In an embodiment, the retainer sidewall 50 has a height, H_(RS), from 2.54 cm (1 inch), or 5.1 cm (2 inches) to 7.6 cm (3 inches), or 10.2 cm (4 inches), or 12.7 cm (5 inches), or 25.4 cm (10 inches), or 38.1 cm (15 inches), or 50.8 cm (20 inches), or 63.5 cm (25 inches), or 76.2 cm (30 inches). In an embodiment, the retainer sidewall 50 has a height, H_(RS), equal to the height, H_(BS), of the sidewall 32 of the base tray 20.

The sidewall 32 of the base tray 20 and retainer sidewall 50 each have a height sufficient to provide a degree of puncture resistance to the flexible container 300. In an embodiment, the height of the sidewall 32 and retainer sidewall 50 are such that graphics or labels on the panels 302 of the flexible containers 300 are visible to a consumer. In another embodiment, the height of the sidewall 32 and retainer sidewall 50 are such that the flexible containers 300 are not visible to a consumer.

In an embodiment, the retainer tray 44 has four corners (52 a, 52 b, 52 c, 52 d), as shown in FIG. 7.

In an embodiment, the retainer tray 44 is formed from an integral retainer platform 46 and retainer sidewall 50, and two other retainer platforms are located above the integral retainer platform 46 and within the retainer sidewall 50.

The retainer sidewall may comprise two or more embodiments disclosed herein.

The retainer tray may comprise two or more embodiments disclosed herein.

D. Second Set of Flexible Containers

In an embodiment, the container storage system 200 includes a second set of flexible containers 316, as shown in FIGS. 8 and 9. The second set of flexible containers 316 includes a plurality of flexible containers, which may include any flexible container previously disclosed.

Each second set flexible container 316 is inverted such that the neck portion 306 extends downward through a respective hole 47 of the retainer platform 46. The closure of at least one second set flexible container 316 contacts a bottom segment 314 of an inverted flexible container 300 on the flat platform 22, as shown in FIG. 8.

FIG. 8 depicts a second set of flexible containers 316 being placed into the container storage system 100. As a second set flexible container 316 is lowered, (i) the neck portion 306 of the second set flexible container 316 extends downward through a respective hole 47 in the retainer platform 46 and (ii) the tapered transition portion 310 contacts the retainer platform 46 and flattens under the weight of the container contents, displacing the contents of the second set flexible container 316. At the same time, the closure, a fitment 308 in FIG. 8, of the second set flexible container 316 contacts a bottom segment 314 of an inverted flexible container 300 on the flat platform 22. The bottom segment 314 of the inverted flexible container 300 on the flat platform 22 is impinged by the closure of the second set flexible container 316 to form a slight positive pressure on the inverted flexible container 300 on the flat platform 22. The tapered transition portion 310 of each second set flexible container 316 contacts the retainer platform 46 to support the second set inverted flexible container 316.

In an embodiment, each of the inverted flexible containers 300 on the flat platform 22 is impinged by a closure of a second set flexible container 316.

One panel 302 of at least one second set inverted flexible container 316 contacts a panel 302 of another second set inverted flexible container 316, as shown in FIG. 8.

FIGS. 9A and 9B depict top plan views of a retainer tray 44 covered by a second set of inverted flexible containers 316. As shown, the covered retainer platform 46 is not visible from the top plan view.

FIG. 9A depicts outer perimeter flexible containers 320. An outer perimeter flexible container 320 has two panels 302 that contact a respective panel 302 from two other outer perimeter flexible containers 320. An outer perimeter flexible container 320 has (i) from 1 to 2 panels 302 that contact the retainer sidewall 50 and (ii) from 2 to 3 panels 302 that contact a respective panel 302 from 2 or 3 other second set flexible containers 316.

FIG. 9B depicts inner flexible containers 322. Each of the four panels 302 of an inner flexible container 322 contacts a respective panel 302 from four other second set flexible containers 316.

The retainer tray 44 and the second set of flexible containers 316 define a retainer layer. The retainer layer has a height, H_(RL), as shown in FIG. 8. In an embodiment, the height of the retainer sidewall 50, H_(RS) is from 10%, or 15%, or 20%, to 25%, or 30%, or 40%, or 50%, or 60%, or 70%, or 75%, or 80%, or 90%, or 95%, or 100% of the height of the retainer layer, H_(RL).

The second set of flexible containers may comprise two or more embodiments disclosed herein.

E. Third Set of Flexible Containers

In an embodiment, a container storage system 400 includes a second retainer tray and a third set of flexible containers 324, as shown in FIG. 10B. The second retainer tray may be any retainer tray previously disclosed herein. The retainer platform of the second retainer tray extends across the bottom segments 314 of the second set of inverted flexible containers 316. The third set of flexible containers 324 may be any flexible container set previously disclosed herein. Each third set flexible container 324 is inverted such that the neck portion 306 extends downward through a respective hole of the second retainer platform. The closure of at least one third set flexible container 324 contacts a bottom segment 314 of a second set inverted flexible container 316.

In an embodiment, the container storage system (200, 400) includes a base tray 20 and alternating sets of inverted flexible containers (300, 316, 324) and retainer trays 44. In an embodiment, the container storage system contains from 1, or 2 to 3, or 4, or 5, or 6, or 7, or 9, or 9, or 10, or 11, or 12, or 13, or 14, or 15, or 16, or 17, or 18, or 19, or 20 sets of inverted flexible containers and from 1, or 2 to 3, or 4, or 5, or 6, or 7, or 9, or 9, or 10, or 11, or 12, or 13, or 14, or 15, or 16, or 17, or 18, or 19, or 20 retainer trays. In an embodiment, the container storage system (200, 400) includes a base tray 20, six sets of inverted flexible containers (300, 316, 324), and five retainer trays 44, wherein the sets of inverted flexible containers (300, 316, 324) and retainer trays 44 alternate.

As shown in FIG. 1, the container storage system 100 has a width, CW, from 50 centimeters (cm), or 60 cm, or 70 cm, or 80 cm, or 90 cm to 100 cm, or 101.6 cm, or 110 cm, or 120 cm, or 121.9 cm, or 130 cm, or 140 cm, or 150 cm, or 200 cm, and a length, CL, from 50 cm, or 60 cm, or 70 cm, or 80 cm, or 90 cm to 100 cm, or 101.6 cm, or 110 cm, or 120 cm, or 121.9 cm, or 130 cm, or 140 cm, or 150 cm, or 200 cm. Container storage system 200 and/or 400 may have the same width, CW, and length, CL, as container storage system 100.

In an embodiment, the container storage system (100, 200, 400) has a width, CW, of 101.6 cm and a length, CL, of 121.9 cm. In a further embodiment, the flat platform 22 has an array of 42 spaced-apart holes 24 and the container storage system (100, 200, 400) contains 42 inverted flexible containers 300 having tapered transition portions 310 contacting the flat platform 22. In a further embodiment, the container storage system (200, 400) includes a retainer tray 44 with a retainer platform 46 having a retainer array of 42 spaced-apart holes 47 and 42 second set inverted flexible containers 316 contacting the retainer platform 46.

F. Upright Post

In an embodiment, the container storage system (100, 200, 400) includes four upright posts 38, as shown in FIGS. 5, 6, 10A, 10B and 11. Each upright post 38 is an L-shaped member.

In an embodiment, each upright post 38 is formed from a paper-board or a corrugated fiberboard. The corrugated fiberboard may be any corrugated fiberboard previously described.

In an embodiment, the base tray 20 has four corners (36 a, 36 b, 36 c, 36 d) and the container storage system (100, 200, 400) further includes an upright post 38 at each of the four corners (36 a, 36 b, 36 c, 36 d), as shown in FIG. 5. In an embodiment, the upright posts 38 extend to the bottom segments 314 of the inverted flexible containers 300.

In an embodiment, the base tray 20 has four corners (36 a, 36 b, 36 c, 36 d), the retainer tray 44 has four corners (52 a, 52 b, 52 c, 52 d) and an upright post 38 extends upward from each of the base tray 20 four corners (36 a, 36 b, 36 c, 36 d) and each of the retainer tray 44 four corners (52 a, 52 b, 52 c, 52 d), as shown in FIG. 11. In an embodiment, the upright posts 38 extend to the bottom segments 314 of the second set inverted flexible containers 316.

The upright post may comprise two or more embodiments disclosed herein.

G. Capboard

In an embodiment, the container storage system (100, 200, 400) includes a capboard 40, as shown in FIGS. 5, 6, 10A, 10B and 11. The capboard 40 is flat. The capboard 40 defines a capboard perimeter edge.

In an embodiment, the capboard 40 is formed from a corrugated fiberboard. The corrugated fiberboard may be any corrugated fiberboard previously described herein. In an embodiment, the capboard 40 is formed from 1, or 2 to 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10 sheets of a corrugated fiberboard.

The capboard 40 has a polygonal shape. The polygonal shape may be any polygonal shape previously disclosed herein. In an embodiment, the capboard 40 has the same polygonal shape as the flat platform 22, as shown in FIG. 5.

In an embodiment, a capboard sidewall extends downward from the capboard peripheral edge. The capboard sidewall may be any sidewall previously disclosed.

The capboard 40 is located above the plurality of inverted flexible containers (300, 316, 324), as shown in FIGS. 5, 6, 10A, 10B and 11. In an embodiment, the capboard 40 extends across the bottom segments 314 of the inverted flexible containers (300, 316, 324). In an embodiment, the capboard 40 is supported by the upright posts 38. In a further embodiment, the capboard 40 is located above the third set of inverted flexible containers 324 and extends across the bottom segments 314 of the third set of inverted flexible containers 324.

The capboard may comprise two or more embodiments disclosed herein.

H. Band Element

In an embodiment, each container storage system (100, 200, 400) includes a band element.

Nonlimiting examples of a suitable band elements include packing straps, film layers 56, and combinations thereof. In an embodiment, each container storage system (100, 200, 400) includes a film layer 56, as shown in FIGS. 6, 10A, 10B and 11. In a further embodiment, each container storage system (100, 200, 400) includes packing straps and a film layer 56.

Nonlimiting examples of suitable materials for packing straps include a metal, a metal alloy such as steel, or a polymeric material. The polymeric material may be any polymeric material previously disclosed herein. In an embodiment, the packing straps are formed from a polymeric material containing a polyester, a propylene-based polymer, and combinations thereof. In an embodiment, each container storage system (100, 200, 400) includes from 1, or 2, or 3 to 4, or 5, or 6, or 7, or 8, or 9, or 10, or 15, or 20 packing straps.

The film layer 56 may be a stretch wrap or a shrink wrap. Nonlimiting examples of suitable materials for a film layer 56 include ethylene-based polymers such as polyethylene (e.g., ELITE™ resins available from The Dow Chemical Company) and linear low density polyethylene (LLDPE) (e.g., DOWLEX™ LLDPE resins available from The Dow Chemical Company); polyvinyl chloride (PVC); copolymers of vinylidene chloride and methyl acrylate, methyl methacrylate or vinyl chloride (e.g., SARAN™ resins available from The Dow Chemical Company); vinylethylene vinyl alcohol (EVOH) copolymer; and combinations thereof. In an embodiment, the band element includes from 1, or 2 to 3, or 4 or 5, or 6, or 7, or 8, or 9, or 10, or 15, or 20 layers of the film layer 56.

In an embodiment, the band element is around the base tray 20, the flexible containers 300, and the capboard 40. In a further embodiment, the band element is around the base tray 20, the flexible containers 300, the upright posts 38 and the capboard 40, as shown in FIG. 6. In a further embodiment, the band element is around the base tray 20, the flexible containers (300, 316, 324), the retainer tray 44, the upright posts 38 and the capboard 40, as shown in FIGS. 10A, 10B and 11.

In an embodiment, a stability substrate is located between the bottom segments 314 of the topmost set of inverted flexible containers (300, 316, 324) and the capboard 40. The stability substrate may be any substrate or platform previously disclosed herein. In an embodiment, the stability substrate is formed from a fiberboard. The fiberboard may be any fiberboard previously disclosed herein. In an embodiment, each container storage system (100, 200, 400) includes from 1, or 2, or 3 to 4, or 5, or 6, or 10 stability substrates.

The stability substrate is placed above the topmost set of flexible containers (300, 316, 324) prior to a band element being applied to the container storage system (100, 200, 400). In an embodiment, each container storage system (100, 200, 400) includes a stability substrate and packing straps around the base tray 20, the flexible containers (300, 316, 324), the retainer tray 44 and the stability substrate. In an embodiment, each container storage system (100, 200, 400) further includes a capboard 40 located above the stability substrate. The packing straps are not around the capboard 40. In an embodiment, each container storage system (100, 200, 400) is then wrapped in a film layer 56, wherein the film layer 56 is wrapped around the base tray 20, the flexible containers (300, 316, 324), the retainer tray 44, the stability substrate, the packing straps, and the capboard 40.

In an embodiment, each container storage system (100, 200, 400) includes two packing straps wrapped around the length of the container storage system (100, 200, 400), and two packing straps wrapped around the width of the container storage system (100, 200, 400).

The band element may comprise two or more embodiments disclosed herein.

I. Pallet

In an embodiment, each container storage system (100, 200, 400) includes a pallet 54, as shown in FIGS. 5, 9, 10A and 10B. A pallet is a flat transport structure that supports items in a stable fashion while being lifted by a forklift 58, a pallet jack, a front loader, a work saver, or other jacking device, or a crane, as shown in FIGS. 10A and 10B.

Nonlimiting examples of suitable pallet 54 materials include wood, corrugated fiberboard, polymeric materials, metals and metal alloys. The corrugated fiberboard may be any corrugated fiberboard previously disclosed herein.

The pallet 54 has a polygonal shape. The polygonal shape may be any polygonal shape previously disclosed herein. In an embodiment, the pallet 54 has the same polygonal shape as the flat platform 22, as shown in FIG. 5.

The pallet 54 has an area suitable to support the area of the base tray 20. Nonlimiting examples of common pallet 54 dimensions are provided in Table 2.

TABLE 2 Common Pallet Dimensions Width Width Length Length Region (cm) (in) (cm) (in) United States 101.6 40.0 121.9 48.0 (and North America generally) Europe, Asia 100.0 39.4 120.0 47.2 Australia 116.5 45.9 116.5 45.9 North America, Europe, Asia 106.7 42.0 106.7 42.0 Asia 110.0 43.3 110.0 43.3 Europe 80.0 31.5 120.0 47.2

In an embodiment, the pallet 54 is a standard United States wood pallet with a width of 101.6 cm (40 inches) and a length of 121.9 cm (48 inches).

In an embodiment, each container storage system (100, 200, 400) includes from 1 to 2 pallets 54. In an embodiment, each container storage system (100, 200, 400) includes a pallet 54 located beneath the base tray 20, as shown in FIGS. 5 and 9. In an embodiment, the pallet 54 contacts the substrate 28. In another embodiment, each container storage system (100, 200, 400) includes a pallet 54 located above the capboard 40. In another embodiment, each container storage system (100, 200, 400) includes a pallet 54 located beneath the base tray 20 and a pallet 54 located above the capboard 40, as shown in FIG. 11.

The pallet may comprise two or more embodiments disclosed herein.

Each container storage system (100, 200, 400) may be placed in a store, such as a club store or grocery store, with consumers. A consumer may grab the bottom handle 312 of a flexible container (300, 3016) to remove it from the container storage system (100, 200, 400). In an embodiment, the flexible container (300, 3016) has graphics or printing that runs in opposing directions on the panels 302 to allow a consumer to read the panels 302 both when the flexible container (300, 3016) is inverted and when the flexible container (300, 316) is not inverted (i.e., upright).

Each container storage system (100, 200, 400) has a space utilization from 35%, or greater than 35%, or 40%, or 45%, or 50%, or 55%, or 60% to 65%, or 70%, or 75%, or 80%, or 85%, or 90%.

Applicant discovered that a container storage system (100, 200, 400) with a plurality of flexible containers (300, 316) (as opposed to rigid containers) results in a container storage system 100 with increased space utilization. Higher space utilization indicates that a higher number of flexible containers (300, 316) may be included in each container storage system (100, 200, 400), which increases the efficiency of transporting the flexible containers (300, 316) and their contents.

Applicant further discovered that space utilization may advantageously be increased by extending the upright posts 38 to the bottom segments 314 of the inverted flexible containers (300, 316, 324), but not past the bottom segments 314. Limiting the height of the upright posts 38 minimizes the empty space of the container storage system (100, 200, 400). Space utilization is also impacted by the presence and size of a pallet 54. The volume occupied by the pallet 54 represents volume of the container storage system (100, 200, 400) that cannot be occupied by flexible containers (300, 316, 324). A standard U.S. wood pallet has a total volume of 157,315 cubic centimeters (cm³) (9,600 cubic inches (in³)). Comparatively, a pallet 54 formed from a sheet of corrugated fiberboard has smaller volume, resulting in higher space utilization.

In an embodiment, each container storage system (100, 200, 400) passes the ISTA 3E test. To pass the ISTA 3E test, a container storage system (100, 200, 400) proceeds through at least Stages 1 and 3-7 of the ISTA 3E test with no visible damage to the container storage system (100, 200, 400) and no pinholing in the flexible containers (300, 316, 324). In a further embodiment, each container storage system (100, 200, 400) has a space utilization of greater than 35%.

A typical manual pallet jack can lift and transport a load of up to 700 kilograms (kg) (1,500 pounds (lbs)) and a typical forklift 58 can lift and transport a load of up to 2,268 kg (5,000 lbs). In an embodiment, each container storage system 100 weighs less than or equal to 2,268 kg (5,000 lbs), or less than or equal to 700 kg (1,500 lbs), or less than or equal to 499 kg (1,100 lbs).

Each container storage system (100, 200, 400) may comprise two or more embodiments disclosed herein.

J. Inverted Container Storage System

In an embodiment, each container storage system (100, 200, 400) may be inverted, as shown in FIG. 14. The container storage system (100, 200, 400) may be any container storage system previously disclosed.

In an embodiment, a container storage system 200 containing a base tray 20, a plurality of flexible containers 300, a capboard 40, upright posts 38, a retainer tray 44, a second set of flexible containers 316, and at least one pallet 54, as shown in FIG. 11, is inverted.

Each container storage system (100, 200, 400) can be inverted by an inversion apparatus 60. FIG. 12 depicts a container storage system 200 and an inversion apparatus 60. As shown, a container storage system 200 with two pallets 54 is placed on the inversion apparatus 60. FIG. 13 depicts the rotation of the container storage system 200 caused by the inversion apparatus 60. After a 180° rotation, the base tray 20 of the container storage system 200 is above the plurality of flexible containers 300, as shown in FIG. 14.

Any present inverted container storage system (100, 200, 400) may be placed in a store with consumers, as shown in FIG. 15. In an embodiment, the base tray 20 is removed from the container storage system (100, 200, 400) so that consumers may easily access the flexible containers (300, 316, 324). An advantage of an inverted container storage system (100, 200, 400) is that consumers can easily read labels or graphics on the panels 302 of the flexible containers (300, 316, 324). Additionally, consumers can grab the top handle 312 of a flexible container (300, 316, 324).

Test Methods

Leak failure mode analysis is performed using a Visual Check International model H hermeticity tester having a submersion chamber. Flexible containers are placed in the submersion chamber and covered with water. The submersion chamber is then closed and a vacuum pump is turned on. Under vacuum pressure, air bubbles release through holes in the flexible containers into the water. Pinholes (i.e., leaks) as fine as 0.002 in (50.8 μm) are detected as a steady stream of bubbles. Leak position is determined by visual observation.

Space utilization is calculated in accordance with Equation (II).

$\begin{matrix} {{{Space}\mspace{14mu} {Utilization}\mspace{14mu} \%} = {\frac{\begin{matrix} {{{total}\mspace{14mu} {volume}\mspace{14mu} {of}\mspace{14mu} {the}}\mspace{11mu}} \\ {{plurality}\mspace{14mu} {of}\mspace{14mu} {flexible}\mspace{14mu} {containers}} \end{matrix}\;}{{total}\mspace{14mu} {volume}\mspace{14mu} {of}\mspace{14mu} {the}\mspace{14mu} {container}\mspace{14mu} {storage}\mspace{14mu} {system}} \times 100}} & {{Equation}\mspace{14mu} ({II})} \end{matrix}$

International Safe Transit Association (ISTA) 3E Testing

ISTA 3E tests are general simulation performance tests designed to provide simulation of damage-producing motions, forces, conditions, and sequences of transport environments. The ISTA 3E test is cumulative, with a passing container storage system proceeding through at least Stages 1 and 3-7 without exhibiting any pinholing or visible damage. Stage 2 is optional. The stages of the ISTA 3E test are provided in Table 3 below. ISTA 3E tests are performed at Compadre Labs of Austin, Tex.

TABLE 3 Stages of ISTA 3E test Stage Test Category Test Type Test Level 1 Atmospheric Temperature and Ambient Preconditioning Humidity 2 Atmospheric Controlled Temperature and Conditioning Temperature and Humidity Pre-Selected (Optional) Humidity 3 Shock Incline Impact 1.1 meter per second (Conbur) (42 inches per second) 4 Shock Rotational Edge Drop 200 mm (8 inches) 5 Compression Weight and Load 3 times the pallet weight Spreader 6 Vibration Random Profile G_(rms) level of 0.54 G (Lansmont Vibration Table, model 6000) 7 Shock Rotational Edge Drop 200 mm (8 inches)

The Incline Impact Shock tests are conducted using a L.A.B. Velocity Monitor, model 1000 VM. During the Incline Impact Shock test, the container storage system is placed on an incline. The container storage system moves at a velocity of at least 1.1 meter/second down the incline and towards a fixed object, and is ultimately impacted by the fixed object. For a container storage system with a base tray 20 having a rectangular shape, each of the four sides of the rectangle are impacted once during the Incline Impact Shock test.

The Rotational Edge Drop Shock test is conducted by placing a container storage system onto a flat, rigid surface such as steel or concrete. One side of the container storage system is supported with a timber or support that is from 90 to 100 mm in height and width. The opposite side of the container storage system is lifted to 200 mm off the surface and released so that it falls freely onto the flat, rigid surface.

The Vibration test of ISTA 3E is conducted to simulate an over 1,127 kilometer (700 mile) shipment by truck. The Vibration test is run for a duration of 3 hours.

By way of example, and not limitation, examples of the present disclosure are provided.

Examples

The materials used to produce container storage systems are provided in Table 4 below.

TABLE 4 Materials Component Specification Integral Base Tray 20 Integral substrate (rectangular) and sidewall formed from a double wall corrugated Substrate 28 and Sidewall fiberboard including a fluted sheet with a B flute and a fluted sheet with a C flute 32 Sidewall height = 5.1 cm (2 in.) Substrate width = 101.6 cm (40 in.) Substrate length = 121.9 cm (48 inches) Flat Platform 22 Rectangular single wall corrugated fiberboard including a fluted sheet with a C flute Flat platform width = 101.6 cm (40 in.) Flat platform length = 121.9 cm (48 in.) Array of 42 spaced-apart holes Support Platform 34 Rectangular single wall corrugated fiberboard including a fluted sheet with a C flute Support platform width = 101.6 cm (40 in.) Support platform length = 121.9 cm (48 in.) Array of 42 spaced-apart holes Integral Retainer Tray 44 Integral retainer platform 46 (rectangular) and retainer sidewall 50 formed from a single wall corrugated fiberboard including a fluted sheet with a C flute Retainer platform width = 101.6 cm (40 in.) Retainer array of 42 spaced-apart holes Retainer platform length = 121.9 cm (48 in.) Retainer sidewall height = 5.1 cm (2 in.) Retainer Platform 46 Rectangular single wall corrugated fiberboard including a fluted sheet with a C flute Retainer platform width = 101.6 cm (40 in.) Retainer array of 42 spaced-apart holes Retainer platform length = 121.9 cm (48 in.) Upright Posts 38 Paper-board, cut to length so that they do not extend past the bottom segments 314 of the third set flexible containers 324 Thickness = 0.635 cm (0.250 in.) L-shaped, extending 6.35 cm (2.5 in.) on each side Stability Substrate Rectangular single wall corrugated fiberboard including a fluted sheet with a C flute Stability Substrate width = 101.6 cm (40 in.) Stability Substrate length = 121.9 cm (48 in.) Capboard 40 Rectangular single wall corrugated fiberboard including a fluted sheet with a C flute Capboard width = 101.6 cm (40 in.) Capboard length = 121.9 cm (48 in.) Flexible Containers PacXpert ™ package with a top handle available from The Dow Chemical Company (300, 316, 324) Volume = 3.8 liters (1 gallon) Fitment = standard white 38 mm screw cap Film Layer 56 7 mil (0.1778 mm) ISO Poly film available from ISO Poly Films, Inc. Packing Straps Polymeric Material Standard U.S. Wood Pallet Pallet shape = rectangle Width = 101.6 cm (40 inches) 54 Length = 121.9 cm (48 inches) Height = 12.7 cm (5 inches)

A. Flexible Container Preparation

PacXpert™ flexible containers (300, 316, 324) with a screw cap fitment 308 inserted into the neck portion 306 are prepared. The tamper evidence band of the screw cap and the cap are removed. The flexible containers (300, 316, 324) are hand-filled with 3.8 liters (1 gallon) of tap water 318. The caps are replaced and hand-tightened without torque control.

The individual flexible containers (300, 316, 324) are weighted. The weight of each individual flexible container (300, 316, 324) filled with 3.8 liters of tap water 318 is 3.63 kg (8 lbs).

B. Container Storage System Example 1

Container storage system Example 1 is detailed in Table 5, below.

TABLE 5 Container Storage System Example Example 1 Standard U.S. Wood Pallet 54 1 Base Tray 20: Integral Base Tray 20 Substrate 28 32 1 and Sidewall Support Platform 34 3 Flat Platform 22 1 First Set of Flexible Containers 300** (6 × 7) 42 First Retainer Tray 44: Integral Retainer Tray 44 1 Retainer Platform 46 2 Second Set Flexible Containers 316** (6 × 7) 42 Second Retainer Tray 44: Integral Retainer Tray 44 1 Retainer Platform 46 2 Third Set Flexible Containers 324** (6 × 7) 42 Upright Posts 38 4 Stability Substrate 1 Packing straps 4 Capboard 40 1 Film Layer 56 (stretch-wrapped with yes 3 layers of film) Total Number of Flexible Containers: 126 Total Volume of Flexible Containers 476,962 cm³ (29,106 in³) Container Storage System Weight 478.5 kg (1,055 lbs) Container Storage System Height 64.14 cm (25.25 in) Total Volume of Container Storage System 794,445 cm³ (48,480 in³) Container Storage System Space Utilization 60% ISTA 3E Test: Stage 1 No Damage Optional Stage 2 — Stage 3 No Damage Stage 4 No Damage Stage 5 No Damage Stage 6 No Damage Stage 7 No Damage Pinholing None **Half of the flexible containers in each set have like orientation (side-to-side-to-side) and half have mixed orientation (side-to-front-to-side).

Container storage system Example 1 is depicted in FIG. 10B. Example 1 includes four packing straps wrapped around the pallet 54, base tray 20, flexible containers 300, retainer tray 44, second set flexible containers 316, second retainer tray 44, third set flexible containers 324, stability substrate and upright posts 38. The packing straps contact the stability substrate extending across the bottom segments 314 of the third set flexible containers 324, but do not contact the bottom segments 314 of the third set flexible containers 324 themselves. Two of the packing straps extend across the length of the container storage system, and two of the packing straps extend across the width of the container storage system. The capboard 40 is placed above the stability substrate and packing straps. Three layers of a film layer 56 are stretch-wrapped around the pallet 54, base tray 20, flexible containers 300, retainer tray 44, second set flexible containers 316, second retainer tray 44, third set flexible containers 324, stability substrate, packing straps, upright posts 38 and capboard 40.

Example 1 is weighed. Example 1 weighs 478.5 kg (1,055 lbs), meaning Example 1 is advantageously suitable for typical manual pallet jacks in club store environments.

Example 1 has a width, CW, of 101.6 cm (40 inches), a length, CL, of 121.9 cm (48 inches), and a total height of 64.14 cm (25.25 inches). The total volume of Example 1 is 794,445 cm³ (48,480 in³), including the pallet 54. The total volume of the 126 flexible containers included in Example 1 is 476,962 cm³ (29,106 in³), meaning Example 1 advantageously achieves a 60% space utilization.

Example 1 is tested in accordance with ISTA 3E. The total duration of the ISTA 3E test is 5 hours. During the Incline Impact Shock test of Stage 3, each of the four sides of the rectangular Example 1 is impacted at a velocity from 1.22 m/s to 1.24 m/s. A load of 1,436 kg (3,165 lbs) (three times the weight of Example 1) is applied above Example 1 during the Compression test of Stage 5. The load is held for a duration of 1 hour and then removed. The flexible containers are observed to bear the majority of the load. After Stages 1 and 3-7 of the ISTA 3E test are complete, no visible damage or leak exists in Example 1.

Example 1 is unpacked to check for pinholing using a using a Visual Check International model H hermeticity tester. No pinholes are observed in any of the 126 flexible containers, and the necks are not damaged. Based on industry standard of ISTA 3E testing, Example 1 passes ISTA 3E testing and is considered shippable.

C. Comparative Container Storage System with Rigid Containers

A comparative container storage system with three sets of 42 rigid 1-gallon plastic containers (each set is a 6×7 array of rigid 1-gallon plastic bottles), each filled with tap water and each having a height of 30.48 cm (12 in.), on a standard U.S. wood pallet and 1.5 inches of corrugated fiberboard distributed throughout system results in a comparative container storage system that has a width of 101.6 cm (40 inches), a length of 121.9 cm (48 inches), and a height of 108.0 cm (42.5 inches). The space utilization of the comparative container storage system with 126 rigid containers is only 35%.

Consequently, Example 1 surprisingly has a space utilization that is almost twice the space utilization of a comparative container storage system with rigid containers. This surprising space utilization results from the fact that the flexible containers, with their positions maintained by the neck constraint layers, adjust their dimensions to maximally contact the surrounding flexible containers. This effect optimally fills the available volume. Rigid containers are not capable of this degree of deformation and require a significant amount of unfilled volume. As space constraints become ever more important in shipping, this effect can be valuable in minimizing the volume required for a shipment.

It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come with the scope of the following claims. 

We claim:
 1. A container storage system comprising: A. a base tray comprising i. a flat platform with a polygonal shape comprising an array of spaced-apart holes, the flat platform defining a perimeter edge; ii. a substrate beneath the flat platform, the substrate defining a peripheral edge, and a sidewall extending upward from the peripheral edge; and B. a plurality of flexible containers on the flat platform, each flexible container having four panels, the four panels forming i. a body portion; ii. a neck portion with a closure; and iii. a tapered transition portion between the body portion and the neck portion; each flexible container inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform above the closure to support the body portion of inverted flexible container; and one panel of at least one inverted flexible container contacts a panel of another inverted flexible container.
 2. The system of claim 1 wherein the base tray further comprises a support platform comprising a support array of spaced-apart holes, the support platform having the same polygonal shape as the flat platform.
 3. The system of claim 1 wherein two panels of each inverted flexible container contact a respective panel from two other inverted flexible containers, and the body portion of each flexible container is a gusseted body portion.
 4. The system of claim 1 wherein the neck portion of each flexible container extends downward through a respective hole in the array; the flat platform is covered by inverted flexible containers; and the container storage system has a space utilization of greater than 35%.
 5. The system of claim 1 wherein the base tray has four corners and the system further comprises an upright post at each corner.
 6. The system of claim 5 comprising a capboard having the same polygonal shape as the flat platform, the capboard supported by the upright posts.
 7. The system of claim 6 comprising a band element around the base tray, flexible containers, the upright posts, and the capboard.
 8. The system of claim 1 comprising: C. a retainer tray comprising i. a retainer platform comprising a retainer array of spaced-apart holes, the retainer platform defining a retainer perimeter edge; ii. a retainer sidewall extending upward from the retainer perimeter edge; the retainer platform extending across bottom segments of the inverted flexible containers; and D. a second set of flexible containers on the retainer tray, each flexible container of the second set inverted such that the neck portion extends downward through a respective hole of the retainer platform; and the closure of at least one flexible container in the second set contacts a base segment of an inverted flexible container on the flat platform.
 9. The system of claim 8 wherein the tapered transition portion of each flexible container in the second set contacts the retainer platform to support the inverted flexible container.
 10. The system of claim 9 wherein one panel of at least one inverted flexible container in the second set contacts a panel of another inverted flexible container in the second set.
 11. The system of claim 10 wherein two panels of each inverted flexible container of the second set contacts a respective panel from two other inverted flexible containers in the second set.
 12. A container storage system comprising: A. a base tray comprising i. a flat platform with a polygonal shape comprising an array of spaced-apart holes, the flat platform defining a perimeter edge; ii. a substrate beneath the flat platform, the substrate defining a peripheral edge, and a sidewall extending upward from the peripheral edge; B. a first set of flexible containers on the flat platform, each flexible container having four panels, the four panels forming i. a body portion; ii. a neck portion with a closure; and iii. a tapered transition portion between the body portion and the neck portion; each flexible container of the first set is inverted such that the neck portion extends downward through a respective hole and the tapered transition portion contacts the flat platform above the closure to support the body portion of the inverted flexible container; C. a retainer tray extending across bottom segments of the inverted flexible containers of the first set, the retainer tray comprising i. a retainer platform, comprising a retainer array of spaced-apart holes, the retainer platform defining a retainer perimeter edge; and ii. a retainer sidewall extending upward from the retainer perimeter edge; and D. a second set of flexible containers on the retainer tray, each flexible container of the second set inverted such that the neck portion extends downward through a respective hole of the retainer platform; and the closure of at least one flexible container in the second set contacts a base segment of an inverted flexible container on the flat platform.
 13. The system of claim 12 wherein for each inverted flexible container, the body portion is above its respective closure.
 14. The system of claim 13 wherein one panel of at least one inverted flexible container in the first set contacts a panel of another inverted flexible container in the first set.
 15. The system of claim 12 wherein the tapered transition portion of each flexible container in the second set contacts the retainer platform to support the inverted flexible container.
 16. The system of claim 15 wherein one panel of at least one inverted flexible container in the second set contacts a panel of another inverted flexible container in the second set.
 17. The system of claim 12 wherein the base tray and the retainer platform each has four corners and the system further comprises an upright post at each corner of the base tray, each upright post extending upward from the corner of the base tray to a corner of the retainer platform.
 18. The system of claim 17 comprising a capboard having the same polygonal shape as the flat platform, the capboard above the second set of flexible containers and supported by the upright posts.
 19. The system of claim 18 comprising a band element around the base tray, the retaining tray, the flexible containers, the upright posts, and the capboard.
 20. The system of claim 12 wherein the container storage system has a space utilization of greater than 35%. 